Powder Reclamation System for Multiple Metal Powder Processing Devices

ABSTRACT

A powder reclamation system is provided. The powder reclamation system includes a support structure; a filter housing movable relative to the support structure, the filter housing defining an inlet and an outlet; a raw reclaimed powder hopper in communication with the inlet of the filter housing; a first reclamation passageway in communication with the raw reclaimed powder hopper and configured to be in communication with a first metal powder processing device to recover a first unused portion of a first powder from the first metal powder processing device to the raw reclaimed powder hopper; and a second reclamation passageway in communication with the raw reclaimed powder hopper and configured to be in communication with a second metal powder processing device to recover a second unused portion of a second powder from the second metal powder processing device to the raw reclaimed powder hopper.

FIELD

The present subject matter relates generally to a powder reclamationsystem, or more particularly to a powder reclamation system that isoperable with multiple metal powder processing devices.

BACKGROUND

Additive manufacturing techniques, processes, or machines refergenerally to manufacturing processes wherein successive layers ofmaterial(s) are provided on each other to “build-up,” layer-by-layer, athree-dimensional component. The successive layers generally fusetogether to form a monolithic component which may have a variety ofintegral sub-components. Some additive manufacturing techniques,processes, or machines involve an energy source that is used toselectively sinter or melt portions of a layer of powder and involvesuccessively depositing layers of additive powder. In such machines,powder removal and collection for additive manufacturing machines may berequired after each machine cycle. Powder removal and/or collection maybe difficult for these machines due to a variety of factors including,e.g., a size and configuration of a printed object due to the size andweight. An efficient powder recycling and sieving process is thusneeded.

BRIEF DESCRIPTION

Aspects and advantages of the invention will be set forth in part in thefollowing description, or may be obvious from the description, or may belearned through practice of the invention.

In one exemplary embodiment of the present disclosure, a powderreclamation system is provided. The powder reclamation system includes asupport structure; a filter housing movable relative to the supportstructure, the filter housing defining an inlet and an outlet; a rawreclaimed powder hopper in communication with the inlet of the filterhousing; a first reclamation passageway in communication with the rawreclaimed powder hopper and configured to be in communication with afirst metal powder processing device to recover a first unused portionof a first powder from the first metal powder processing device to theraw reclaimed powder hopper; and a second reclamation passageway incommunication with the raw reclaimed powder hopper and configured to bein communication with a second metal powder processing device to recovera second unused portion of a second powder from the second metal powderprocessing device to the raw reclaimed powder hopper.

In an exemplary aspect of the present disclosure, a method of reclaimingpowder using a powder reclamation system is provided. The methodincludes recovering a first unused portion of a first powder from afirst metal powder processing device; recovering a second unused portionof a second powder from a second metal powder processing device;providing the first unused portion of the first powder and the secondunused portion of the second powder to a housing of a powder reclamationsystem comprising a separator; separating a first portion of the firstand second powders from a second portion of the first and second powdersusing the separator; recirculating a first part of the second portion ofthe first and second powders back to the first metal powder processingdevice; and recirculating a second part of the second portion of thefirst and second powders back to the second metal powder processingdevice.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the invention and, together with the description, serveto explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendedfigures, in which:

FIG. 1 is a perspective view of a powder sieving system utilizing abroad frequency filter that is part of a powder reclamation system inaccordance with an exemplary embodiment of the present disclosure.

FIG. 2 is an enlarged perspective view of a powder sieving systemutilizing a broad frequency filter that is part of a powder reclamationsystem in accordance with an exemplary embodiment of the presentdisclosure.

FIG. 3 is a perspective view of a powder sieving system, a first motor,and a second motor that are part of a powder reclamation system inaccordance with an exemplary embodiment of the present disclosure.

FIG. 4 is a perspective view of a powder sieving system utilizing abroad frequency filter that is part of a powder reclamation system inaccordance with an exemplary embodiment of the present disclosure.

FIG. 5 is a cross-sectional view of a broad frequency filter of a powdersieving system, with enlarged views of a portion of a first filter and asecond filter, in accordance with an exemplary embodiment of the presentdisclosure.

FIG. 6 is a cross-sectional view of a broad frequency filter of a powdersieving system, with a second filter moved away from a first filter, inaccordance with an exemplary embodiment of the present disclosure.

FIG. 7 is a cross-sectional view of a portion of a broad frequencyfilter of a powder sieving system in accordance with an exemplaryembodiment of the present disclosure.

FIG. 8 is a side perspective view of a portion of a powder sievingsystem in accordance with an exemplary embodiment of the presentdisclosure.

FIG. 9 is another side perspective view of a portion of a powder sievingsystem that is part of a powder reclamation system in accordance with anexemplary embodiment of the present disclosure.

FIG. 10 is a perspective view of a portion of a powder sieving systemthat is part of a powder reclamation system in accordance with anexemplary embodiment of the present disclosure.

FIG. 11 is a cross-sectional view of a second portion of a broadfrequency filter in accordance with an exemplary embodiment of thepresent disclosure.

FIG. 12 is a perspective view of a powder reclamation system incommunication with a metal powder processing device in accordance withan exemplary embodiment of the present disclosure.

FIG. 13 is a perspective view of a raw reclaimed powder hopper that ispart of a powder reclamation system, with a side cross-sectional view ofthe raw reclaimed powder hopper, in accordance with an exemplaryembodiment of the present disclosure.

FIG. 14 is a perspective view of a powder sieving system in accordancewith an exemplary embodiment of the present disclosure.

FIG. 15 is a side perspective view of a powder sieving system inaccordance with an exemplary embodiment of the present disclosure.

FIG. 16 is a cross-sectional view of a broad frequency filter having afirst filter assembly and a second filter assembly in accordance withanother exemplary embodiment of the present disclosure.

FIG. 17 is a cross-sectional view of a second portion of a broadfrequency filter having a first filter assembly and a second filterassembly in accordance with another exemplary embodiment of the presentdisclosure.

FIG. 18 is a perspective view of a powder reclamation system incommunication with a metal powder processing device in accordance withan exemplary embodiment of the present disclosure.

FIG. 19 is a perspective view of a powder reclamation system incommunication with a first metal powder processing device and a secondmetal powder processing device in accordance with another exemplaryembodiment of the present disclosure.

FIG. 20 is a flow diagram of a method of reclaiming powder in accordancewith an exemplary aspect of the present disclosure.

FIG. 21 is a flow diagram of a method reclaiming powder in accordancewith another exemplary aspect of the present disclosure.

FIG. 22 is a flow diagram of a method of reclaiming powder in accordancewith another exemplary aspect of the present disclosure.

FIG. 23 is a flow diagram of a method of reclaiming powder using apowder reclamation system in accordance with another exemplary aspect ofthe present disclosure.

FIG. 24 is a flow diagram of a method of operating a sieving system inaccordance with an exemplary aspect of the present disclosure.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate exemplary embodiments of the disclosure, and suchexemplifications are not to be construed as limiting the scope of thedisclosure in any manner.

DETAILED DESCRIPTION

Reference will now be made in detail to present embodiments of theinvention, one or more examples of which are illustrated in theaccompanying drawings. The detailed description uses numerical andletter designations to refer to features in the drawings. Like orsimilar designations in the drawings and description have been used torefer to like or similar parts of the invention.

The following description is provided to enable those skilled in the artto make and use the described embodiments contemplated for carrying outthe invention. Various modifications, equivalents, variations, andalternatives, however, will remain readily apparent to those skilled inthe art. Any and all such modifications, variations, equivalents, andalternatives are intended to fall within the spirit and scope of thepresent invention.

For purposes of the description hereinafter, the terms “upper”, “lower”,“right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”,“longitudinal”, and derivatives thereof shall relate to the invention asit is oriented in the drawing figures. However, it is to be understoodthat the invention may assume various alternative variations, exceptwhere expressly specified to the contrary. It is also to be understoodthat the specific devices illustrated in the attached drawings, anddescribed in the following specification, are simply exemplaryembodiments of the invention. Hence, specific dimensions and otherphysical characteristics related to the embodiments disclosed herein arenot to be considered as limiting.

As used herein, the terms “first”, “second”, and “third” may be usedinterchangeably to distinguish one component from another and are notintended to signify location or importance of the individual components.The terms “upstream” and “downstream” refer to the relative directionwith respect to fluid flow in a fluid pathway. For example, “upstream”refers to the direction from which the fluid flows, and “downstream”refers to the direction to which the fluid flows.

A powder reclamation system of the present disclosure allows for therecovery, sieving, and recirculation of unused portions of powder fromone or more metal powder processing devices. A powder reclamation systemof the present disclosure includes a multiple metal powder processingdevice attachment assembly that allows for a powder reclamation systemof the present disclosure to connect to and recover powder from aplurality of metal powder processing devices.

Referring now to the drawings, wherein identical numerals indicate thesame elements throughout the figures, FIGS. 1-23 illustrate variousexemplary embodiments of the present disclosure. More specifically,referring first to FIGS. 1-13, generally, a powder reclamation system 10in accordance with an exemplary embodiment of the present disclosure isprovided. More specifically, still, referring to FIGS. 1-2, theexemplary powder reclamation system 10 is depicted. FIG. 1 provides afront view of the exemplary powder reclamation system, and FIG. 2provides a rear view of the exemplary powder reclamation system 10. Aswill be appreciated from FIGS. 1 and 2, and the description herein, theexemplary powder reclamation system generally includes a powder sievingsystem assembly 12, a broad frequency filter assembly 14, a powder masscontrol assembly 16, an isolation assembly 18, a new or virgin powderassembly 20, an oxygen sensing assembly 24, and a carrier gas assembly28. Notably, for the embodiment shown, the broad frequency filterassembly 14, the powder mass control assembly 16, and the isolationassembly 18 are each configured as part of the exemplary powder sievingassembly 12.

As will be explained in greater detail below, the powder reclamationsystem 10 is generally configured to receive a reclaimed powder from ametal powder processing device 100 (FIGS. 12 and 18), sieve the powder,and provide the sieved powder (along with a desired amount of virginpowder) back to the metal powder processing device. For the embodimentdepicted, the powder reclamation system 10 generally includes a rawreclaimed powder hopper 54 for receiving the reclaimed powder, a filterhousing 32 downstream of the raw reclaimed powder hopper 54 forreceiving a raw reclaimed powder from the raw reclaimed powder hopper54, a filtered reclaimed powder hopper 56 for receiving a sievedreclaimed powder from the filter housing 32, an oversized powder hopper72 for receiving an oversized portion of the raw reclaimed powder hopper54 from the filter housing 32 (see FIG. 2), a virgin powder hopper 132arranged in parallel with the filtered reclaimed powder hopper 56 and anetwork of passageways 166 connecting the various hopper and features ofthe reclamation system to one another and to a metal powder processingdevice 100.

As will be appreciated from the description herein, the raw reclaimedpowder hopper 54, the filter housing 32, and the filtered reclaimedpowder hopper 56 (and certain other aspects) may be configured as astand-alone sieving system, and may not be incorporated into a powderreclamation system (see, e.g., the embodiment of FIG. 14, discussedbelow).

Referring particularly to the filter housing 32, in the exemplaryembodiment depicted, the filter housing 32 includes a broad frequencyfilter assembly 14. The broad frequency filter assembly 14 of thepresent disclosure restricts a first portion 27 of a powder 26 (FIGS. 5and 6) larger than a predetermined threshold and allows a second portion29 of the powder 26 (FIGS. 5 and 6) smaller than the predeterminedthreshold to pass therethrough.

It is also contemplated that the broad frequency filter 14 may include aseparator that is configured to separate a first portion of the powderfrom a second portion of the powder. For example, the broad frequencyfilter 14 including a separator, in addition to being able to filter bypowder sizes, may also be able to separate based on different types ofpowders, to remove clumps, and/or other separation criteria.

Referring to FIGS. 3 through 5, aspects of the filter housing 32 andbroad frequency filter 14 will be described. FIG. 3 provides a close-upview of the filter housing 32 of FIGS. 1-2, FIG. 4 provides a close-up,cross-sectional view of the filter housing 32 of FIG. 3, and FIG. 5provides a close-up, cross-sectional view of the broad frequency filterassembly 14. In the exemplary embodiment depicted, the powderreclamation system 10 further includes a support structure 30, with thefilter housing 32 being movable relative to the support structure 30.The filter housing 32 defines an inlet 34 and an outlet 36 and includesthe broad frequency filter assembly or broad frequency filter 14disposed between the inlet 34 and the outlet 36 of the filter housing32.

Referring particularly to FIG. 5, in an exemplary embodiment, the broadfrequency filter 14 includes a first filter 40 and a second filter 42.The first filter 40 is fixed relative to the filter housing 32. In oneembodiment, the first filter 40 is substantially rigid, e.g., the firstfilter 40 is substantially fixed relative to the filter housing 32. Forexample, in at least certain exemplary embodiments, the first filter 40may be configured to deflect or flex a maximum of less than about 0.5inches during normal operations. The second filter 42 is coupled withinthe filter housing 32 adjacent to the first filter 40. Morespecifically, the second filter 42 is coupled within the filter housing32 such that the second filter 42 contacts the first filter 40 duringoperation of the broad frequency filter 14.

In one embodiment, the second filter 42 is substantially flexible, i.e.,the second filter 42 is movable relative to the first filter 40 withinthe filter housing 32 when the filter housing 32 moves relative to thesupport structure 30. For example, referring now also to FIG. 6,providing another close-up view of the broad frequency filter assembly14, with the second filter 42 in a deflected position, the second filter42 is movable relative to the first filter 40 within the filter housing32 from a first, initial position (FIG. 5) to a second, maximumdeflection position (FIG. 6). As is depicted in FIG. 6, in an exemplaryembodiment, when the second filter 42 is in the maximum deflectionposition, the second filter 42 defines a maximum deflection away fromthe first filter 40 greater than ¼ inch and less than 5 inches. It iscontemplated that in the maximum deflection position, the second filter42 may be spaced other distances away from the first filter 40. Forexample, in another exemplary embodiment, in the maximum deflectionposition, the second filter 42 defines a maximum deflection away fromthe first filter 40 greater than ¼ inch and less than 4 inches. Inanother exemplary embodiment, in the maximum deflection position, thesecond filter 42 defines a maximum deflection away from the first filter40 greater than ¼ inch and less than 3 inches. In another exemplaryembodiment, in the maximum deflection position, the second filter 42defines a maximum deflection away from the first filter 40 greater than¼ inch and less than 2 inches. In another exemplary embodiment, in themaximum deflection position, the second filter 42 defines a maximumdeflection away from the first filter 40 greater than ¼ inch and lessthan 1 inch. In another exemplary embodiment, in the maximum deflectionposition, the second filter 42 defines a maximum deflection away fromthe first filter 40 greater than ½ inch and less than 1 inch.

As will be appreciated, the maximum deflection is defined in a directionperpendicular to a reference plane defined by the first filter. Themovement of the second filter to the maximum deflection position iscaused by a movement of the filter housing in a generally verticaldirection by a plurality of motors, as well be explained in greaterdetail below with reference to, e.g., FIGS. 8 and 9.

The first filter 40 and the second filter 42 of the broad frequencyfilter 14 are configured to restrict a first portion 27 of a powder 26larger than a predetermined threshold from reaching the outlet 36 of thefilter housing 32 and to allow a second portion 29 of the powder 26,i.e., filtered reclaimed or recycled powder 29, smaller than thepredetermined threshold to pass through the first filter 40, the secondfilter 42, and the outlet 36 of the filter housing 32. In an exemplaryembodiment, the predetermined threshold of the first filter 40 and thesecond filter 42 of the broad frequency filter 14 is approximately 15μm. In another exemplary embodiment, the predetermined threshold of thefirst filter 40 and the second filter 42 of the broad frequency filter14 is approximately 150 μm. It is contemplated that the predeterminedthreshold of the first filter 40 and the second filter 42 of the broadfrequency filter 14 may include other sizes. For example, in otherexemplary embodiments, the predetermined threshold of the first filter40 and the second filter 42 of the broad frequency filter 14 may beanywhere from approximately 15 μm to approximately 150 μm.

In order to facilitate such selective passage of the second portion ofthe powder therethrough, the first and second filters define a pluralityof pores. More particularly, referring to the close-up portion 5A ofsecond filter 42 and close-up portion 5B of first filter 40 in FIG. 5,the first filter 40 defines a plurality of first pores 48 extendingthrough a thickness of the first filter 40 and the second filter 42defines a plurality of second pores 49 extending through a thickness ofthe second filter 42. Notably, the views in the close-up portion 5A ofsecond filter 42 and close-up portion 5B of first filter 40 in FIG. 5are top-down views of a surface of the first filter 40 and second filter42, respectively. In certain embodiments, the plurality of first pores48 may each define a size (e.g., width) less than a size of theplurality of second pores 49. Alternatively, however, the first andsecond pores 48, 49 may all be substantially the same size.

During operation of the broad frequency filter 14, as noted above, thesecond filter 42 moves between the initial position and the maximumdeflection position, as a result of a generally vertical movement of thefilter housing 32. Such movement causes the second filter 42 to contactthe first filter 40, or “slap” the first filter 40. Such contact mayreduce an amount of clogging or blockage within the first and secondpores 48, 49 of the first and second filters 40, 42, resulting in arelatively efficient process.

In an exemplary embodiment, the first filter 40 and the second filter 42are metallic filters. For example, in one embodiment, the first filter40 and the second filter 42 are formed of a stainless steel. However, itis contemplated that the first filter 40 and the second filter 42 may beformed of other materials, e.g., other metallic materials.

In one embodiment, a powder reclamation system 10 of the presentdisclosure is configured to recover, filter, and recirculate a powder.The powder may be a reactive metal powder (i.e., may be formed of ametal powder that reacts with oxygen), such as a titanium or titaniumalloy powder. Alternatively, the powder may consist of, e.g., analuminum powder or other suitable powder.

Furthermore, referring still to FIGS. 5 and 6, the filter housing 32includes a mounting assembly 43 and a seal 44 for mounting and sealingthe first and second filters 40, 42 of the broad frequency filter 14within the filter housing 32. For example, the mounting assembly 43provides a mechanism for mounting the first filter 40 adjacent to thesecond filter 42 within the filter housing 32. Specifically, for theembodiment shown, the mounting assembly 43 of the filter housing 32includes a first circumferential flange 51 and a second circumferentialflange 53, and a coupling 55 extending between the first and secondcircumferential flanges 51, 53. The coupling 55 may be a nut, aplurality of bolts or screws, a clamp, etc. When assembled the coupling55 presses the first and second circumferential flanges 51, 53 together.Notably, a circumferential end or outside edge 45 of the first filter 40and a circumferential end or outside edge 46 of the second filter 42 arepositioned between the first and second circumferential flanges 51, 53,such that when assembled, the first and second filters 40, 42 are fixedin position within the filter housing 32.

Moreover, referring now also to FIG. 7, a close-up, cross-sectional viewof the mounting assembly 43 is provided. The above-describedconfiguration is depicted with additional clarity. In addition, for theembodiment depicted, the filter housing 32 also includes a continuousU-shaped seal 44 that extends around an outside edge 45 of the firstfilter 40 and around an outside edge 46 of the second filter 42. Theseal 44 ensures a sealed environment of the filter housing 32 so that noportion of powder 26 escapes or plumes out of the filter housing 32.More specifically, for the embodiment depicted, the filter housing 32defines an upstream portion 57 located upstream of the first and secondfilters 40, 42 and a downstream portion 59 located downstream of thefirst and second filters 40, 42. The U-shaped seal 44 extendscontinuously from the upstream portion 57, around the outside edges 45,46 of the first and second filters 40, 42, to the downstream portion 59.In such a manner, any powder that makes its way between the seal 44 andthe outside edges 45, 46 of the first and second filters 40, 42 can onlytravel to the downstream portion 59 of the filter housing 32 (and not toan ambient location outside of the filter housing 32). It will beappreciated that any powders small enough to travel between the firstand second filters 40, 42 and the U-shaped seal 44 will most likely besmaller than the first and second pores 48, 49 (FIG. 5).

Referring back to FIGS. 1 and 2, as briefly mentioned above, the broadfrequency filter 14 is effective at least in part as a result of thegenerally vertical movement of the filter housing 32 during operation.As is depicted, the powder sieving system assembly 12 of the presentdisclosure (which as noted above is incorporated into the exemplarypowder reclamation system 10) includes a vibration assembly 90 forproviding and controlling movement of the filter housing 32 relative tothe support structure 30 and the second filter 42 relative to the firstfilter 40. In one exemplary embodiment, the vibration assembly 90includes a first motor 91 and a second motor 92. The first motor 91 ispositioned relative to a portion of the filter housing 32 via a firstmotor mounting assembly 93 and the second motor 92 is positionedrelative to a portion of the filter housing 32 via a second motormounting assembly 94. In one embodiment, the first motor 91 is a firstlinear displacement motor and the second motor 92 is a second lineardisplacement motor. In this manner, the first motor 91 and the secondmotor 92 provide linear movement to the filter housing 32 relative tothe support structure 30.

Referring now also to FIGS. 8 and 9, the first motor 91 is depicted anddescribed in greater detail. FIG. 8 provides a perspective view of thefirst motor 91 mounted to the filter housing via the first motormounting assembly 93, and FIG. 9 provides a straight-on view of thefirst motor 91 mounted to the filter housing via the first motormounting assembly 93.

As will be appreciated from FIGS. 8 and 9, the filter housing 32 definesa longitudinal axis 110, which for the embodiment depicted is parallelto a vertical direction. Additionally, the first motor 91 is a firstlinear displacement motor configured to move along a first displacementaxis 112. In an exemplary embodiment, the first displacement axis 112defines a first angle 116 with the longitudinal axis 110 greater thanabout 15 degrees and less than about 85 degrees.

As is further depicted, the first motor 91 is adjustably mounted to aportion of the filter housing 32 via the first motor mounting assembly93 such that the first motor 91 is adjustably mounted to adjust an anglebetween the first displacement axis 112 and the longitudinal axis 110.Specifically, the first motor mounting assembly 93 includes a plate 95with a plurality of mounting holes or openings 96, as well as a bracket97 fixed to the first motor 91. The bracket 97 is mountable to the plate95 using the plurality of mounting holes 96. By choosing the mountingholes 96 utilized to mount the bracket 97 to the plate 95, the firstangle 116 between the longitudinal axis 110 and the first displacementaxis 112 may be modified.

Furthermore, although not depicted in detail in FIGS. 8 and 9, it willbe appreciated that the second motor 92 and second motor mountingassembly 94 may be configured in substantially the same manner as thefirst motor 91 and first motor mounting assembly 93. In such a manner,it will be appreciated that the second motor 92 may define a seconddisplacement axis that defines an angle with the longitudinal axis 110of the filter housing 32 similar to the first angle 116 (or differentthan the first angle 116). Further, in such a manner it will beappreciated that the second motor 92 may be adjustably mounted to aportion of the filter housing 32 via the second motor mounting assembly94 such that the second motor 92 is adjustably mounted to adjust anangle between the second displacement axis and the longitudinal axis110.

Notably, however, in other embodiments, the first and second motors 91,92 may be configured in any other suitable manner. For example, in otherembodiments, the motors 91, 92 may define any other angle with thelongitudinal axis 110, may be mounted to the filter housing 32 in anyother suitable manner, etc. Further, although two motors 91, 92 areshown, in other embodiments, the vibration assembly 90 may include anyother suitable number or arrangement of motors.

Briefly, referring still to FIGS. 8 and 9 (and as may also be seen,e.g., in FIGS. 1 and 2), the powder reclamation system 10 of the presentdisclosure further includes a plurality of dampers 58 that extendbetween the support structure 30 and the filter housing 32 formechanically isolating a movement of the filter housing 32 duringoperation of the powder sieving system assembly 12 and/or powderreclamation system 10. In one embodiment, the plurality of dampers 58may comprise a plurality of springs 70. More specifically, the exemplarysystem 10 depicted includes a plate 98 coupled to the support structure30 and a mounting ring 99 coupled to the filter housing 32. Theplurality of dampers 58 extend between the plate 98 and the mountingring 99.

It will be appreciated that the angle of the motors 91, 92 may generallybe used to assist with the spreading of powder along a top surface ofthe filters 40, 42 in addition to the provision of the generallyvertical movement to facilitate the second filter 42 moving relative to,and hitting against, the first filter 40. More specifically, it will beappreciated that by angling the first and second motors 91, 92, acentrifugal force component is applied to the powder on top of the firstfilter 40, forcing the powder too large to fit through the pores 48 ofthe first filter 40 towards the outer edge of the first filter 40.

More specifically, referring now also to FIGS. 10 and 11, providing across-sectional view of the filter housing 32 having an oversized powderor second outlet 38, and a close-up of the oversized powder outlet 38,respectively, it will be appreciated that the filter housing 32 alsodefines a second outlet 38 (i.e., an oversized powder outlet) that ispositioned upstream of the first filter 40 and the second filter 42 forreceiving the first portion 27 of the powder 26 that is larger than thepredetermined threshold and that is restricted by the broad frequencyfilter 14 from passing therethrough. Advantageously, the movement of thesecond filter 42 relative to the first filter 40 and the movement of thefilter housing 32 relative to the support structure 30 helps to move thefirst portion 27 of the powder 26 to the second outlet 38. Morespecifically, as discussed above, the angled orientation of the firstand second motors 91, 92 generates a centrifugal force that urges thepowder 26 towards the outer edge 45 of the first filter 40, allowing thepowder 26 to spread over the first filter 40, and for the powder 26 thatdoesn't pass through the first filter 40 to be ejected from the filterhousing 32 through the second opening 38 to an oversized powder hopper72 (see FIG. 2).

In an exemplary embodiment, the powder reclamation system 10, the powdersieving system assembly 12, and the broad frequency filter assembly 14of the present disclosure include an oversized powder hopper 72 (seeFIG. 2) that is positioned downstream of the second outlet 38 of thefilter housing 32, e.g., the oversized powder hopper 72 and the secondoutlet 38 of the filter housing 32 are in flow communication. In thismanner, the first portion 27 of the powder 26 that does not pass throughthe broad frequency filter 14 moves through the second outlet 38 of thefilter housing 32 and is collected within the oversized powder hopper72.

Notably, in an exemplary embodiment, a powder reclamation system 10 ofthe present disclosure includes an isolation assembly 18 for isolating apowder 26 traveling through a powder reclamation system 10 to only comeinto contact with metallic portions to prevent contamination of thepowder 26 with non-metallic portions. The isolation assembly 18 mayfacilitate such isolation despite the movement of the filter housing 32described above generated by the vibration assembly 90 relative to thesupport structure 30, and the raw reclaimed powder hopper 54, thefiltered reclaimed powder hopper 56, and the oversized powder hopper 72.

More specifically, referring now to FIGS. 4 and 10, providing close upviews of the isolation assembly 18 at the connection between the rawreclaimed powder hopper 54 and the filter housing 32, and between thefilter housing 32 and the filtered reclaimed powder hopper 56,respectively, the isolation assembly 18 includes powder passageways 121that include a flexible mounting portion 120, 124 and a metallic linerportion 122, 126 that is respectively positioned within the flexiblemounting portion 120, 124. For example, referring particularly to theembodiment depicted in FIG. 4, the isolation assembly 18 includes afirst flexible mounting 120 that extends between the raw reclaimedpowder hopper 54 and the inlet 34 of the filter housing 32 and a firstmetallic liner 122 that is positioned within the first flexible mounting120 and is fixed to one of the raw reclaimed powder hopper 54 or theinlet 34 of the filter housing 32. In particular, for the embodimentdepicted, the first metallic liner 122 is fixed to the raw reclaimedpowder hopper 54, such that the first metallic liner 122 does not movewith the filter housing 32 when the filter housing 32 is vibrated usingthe vibration assembly 90.

Similarly, referring particularly to FIGS. 4 and 10, the isolationassembly 18 includes a second flexible mounting 124 that extends betweenthe outlet 36 of the filter housing 32 and the filtered reclaimed powderhopper 56 and a second metallic liner 126 that is positioned within thesecond flexible mounting 124 and is fixed to one of the filteredreclaimed powder hopper 56 or the outlet 36 of the filter housing 32. Inparticular, for the embodiment depicted, the second metallic liner 126is fixed to the filter housing 32, such that the second metallic liner126 is configured to move with the filter housing 32 relative to thefiltered reclaimed powder hopper 56 when the filter housing 32 isvibrated using the vibration assembly 90.

In this manner, a powder 26 traveling through a powder reclamationsystem 10 only comes into contact with metallic portions, i.e., themetallic liner portions 122, 126, to prevent contamination of the powder26 with non-metallic portions, i.e., the flexible mounting portions 120,124. Furthermore, this configuration allows for the flexible mountingportions 120, 124 to expand and contract along with the movement of thepowder sieving system 12 during operation. In certain exemplaryembodiments, the metallic liners 122, 126 may be, e.g., a stainlesssteel or other suitable material. By contrast, the flexible mountings120, 124 may be an elastomeric or other flexible material.

As will further be appreciated from the description herein, a powderreclamation system 10 in accordance with one or more embodiments of thepresent disclosure is able to recover unused portions of powder 26 froma metal powder processing device, sieve the powder to a desired sizedistribution, and then return the powder to the metal powder processingdevice (along with some virgin powder, as desired).

As used herein, the term “metal powder processing device” refers to anymetal powder processing device or system such as additive manufacturingmachines, powder removal devices or systems, mixing stations, or othermetal powder processing devices or systems. Furthermore, portions of apowder reclamation system or portions of a powder sieving system of thepresent disclosure are configured to be in communication with such metalpowder processing devices. As used herein, the term “in communicationwith” refers to any type of connection or attachment between portions ofa powder reclamation system or portions of a powder sieving system ofthe present disclosure with such metal powder processing devices forrecovering a portion of a powder from the metal powder processingdevices.

More specifically, referring now also to FIGS. 12 and 18, a powderreclamation system 10 of the present disclosure is depicted inconnection with a metal powder processing device 100. As noted above,the powder reclamation system 10 includes a network of passageways 166,a raw reclaimed powder hopper 54, a filtered reclaimed powder hopper 56,and a plurality of dampers 58. The network of passageways 166 connectsthe various hopper and features of the reclamation system 10 to oneanother and to a metal powder processing device 100. In particular, forthe embodiment depicted, the network of passageways 166 includes areclamation passageway 50 and a recirculation passageway 52.

During reclamation operations of the powder reclamation system 10, thereclamation passageway 50 is configured to receive unused powder fromthe metal powder processing device 100. The unused powder may betransported through the reclamation passageway 50 by flowing a carriergas through the metal powder processing device 100 and from the metalpowder processing device 100 through the reclamation passageway 50.

Referring still to FIGS. 12 and 18, in an exemplary embodiment, the rawreclaimed powder hopper 54 is in communication with the inlet 34 of thefilter housing 32. The raw reclaimed powder hopper 54 receives an unusedportion of a powder 26 from the metal powder processing device 100. Inone embodiment, the reclamation passageway 50 is in communication withthe inlet 34 of the filter housing 32 and is configured to recover theunused portion of the powder 26 from the metal powder processing device100. For example, in one embodiment, the reclamation passageway 50 is incommunication with the raw reclaimed powder hopper 54 and a metal powderprocessing device 100. In this manner, the reclamation passageway 50provides a conduit or channel to recover an unused portion of a powder26 from the metal powder processing device 100 to the raw reclaimedpowder hopper 54 which is in communication with the inlet 34 of thefilter housing 32. A powder 26 travels through the reclamationpassageway 50 to the raw reclaimed powder hopper 54 and through theinlet 34 of the filter housing 32 to the broad frequency filter 14 forfiltering.

Referring now briefly also to FIG. 13, providing a side, cross-sectionalview of the raw reclaimed powder hopper 54, the raw reclaimed powderhopper 54 is described in more detail. As shown, the raw reclaimedpowder hopper 54 depicted defines a raw powder inlet 60, a raw powderoutlet 62 in communication with the inlet 34 of the filter housing 32,and a carrier gas outlet 64. The reclamation passageway 50 extends tothe raw powder inlet 60 of the raw reclaimed powder hopper 54. For theembodiment shown, the inlet 60 is positioned in a side of the rawreclaimed powder hopper 54 and oriented at an angle relative to acenterline of the raw reclaimed powder hopper 54 (see also, e.g., FIG.2). In such a manner, an outer wall 68 of the raw reclaimed powderhopper 54 may act as a gravity-operated separator, such that the heavierpowder falls to a bottom end of the raw reclaimed powder hopper 54 andthe lighter carrier gas rises to a top end of the raw reclaimed powderhopper 54. In such a manner, it will further be appreciated that thecarrier gas outlet 64 is positioned at a top end of the raw reclaimedpowder hopper 54 and the powder outlet 62 is positioned at a bottom endof the raw reclaimed powder hopper 54.

The raw reclaimed powder hopper 54 also includes a powder filter 66within the carrier gas outlet 64 for removing powder from a carrier gasflow through the carrier gas outlet 64. The powder filter 66 isconfigured to prevent or reduce any powder received through the rawpowder inlet 60 of the raw reclaimed powder hopper 54 from passingthrough the carrier gas outlet 64 of the raw reclaimed powder hopper 54.The powder filter 66 is, for the embodiment depicted, formed of a metalmaterial to reduce a contamination of any powder filtered out of thecarrier gas by the powder filter 66. More specifically, it will beappreciated that for the exemplary system depicted, the powder 26 isformed of a material and the powder filter 66 is formed substantially ofthe same material (e.g., titanium or a titanium allow). Such may furtherreduce a risk of the powder 26 being contaminated.

It will be appreciated, however, that in other embodiments, the powderfilter 66 may be formed of any other suitably material, such as astainless steel material.

Further, it will be appreciated that for the embodiment depicted, theraw reclaimed powder hopper 54 includes a plurality of powder filters 66arranged in parallel flow, and more specifically still includes fourpowder filters. Each of the plurality of powder filters 66 may be formedof a metal material to reduce a risk of contamination of the powderfiltered out of the carrier gas.

Moreover, the powder filters 66 depicted are each in airflowcommunication with a high pressure gas source, such as a high pressurecarrier gas source 180. The high pressure gas source may be configuredto selectively flow high pressure gas in a direction opposite a normalgas flow direction through the filters 66. In such a manner, the highpressure gas source may be configured to “purge” the filters 66.

Referring back to FIGS. 1-2, as noted above, the reclamation system 10further includes the filtered reclaimed powder hopper 56. The filteredreclaimed powder hopper 56 is in communication with the outlet 36 of thefilter housing 32. As explained in greater detail above, the filterhousing 32 receives the raw reclaimed powder from the raw reclaimedpowder hopper 54, filters the powder to obtain a desired powder sizedistribution (e.g., separates a second portion 29 of the powder 26 froma first portion 27 of the powder 26) using a filter 14, and provides thesecond portion 29 of the powder 26 to the outlet 36 of the filterhousing 32. The filtered reclaimed powder hopper 56 receives the secondportion 29 of the powder 26, i.e., filtered reclaimed or recycled powder29, that passes through the first filter 40 and the second filter 42. Inone embodiment, a recirculation passageway 52 is in communication withthe outlet 36 of the filter housing 32 and is configured to recirculatethe second portion 29 of the powder 26 that passes through the firstfilter 40 and the second filter 42 back to the metal powder processingdevice 100. More specifically, for the embodiment shown, therecirculation passageway 52 is in communication with the filteredreclaimed powder hopper 56 and the metal powder processing device 100.In this manner, the recirculation passageway 52 provides a conduit orchannel to recirculate the second portion 29 of the powder 26 collectedwithin the filtered reclaimed powder hopper 56 back to the metal powderprocessing device 100.

A reclamation system and/or a sieving system assembly of the presentdisclosure can be configured to recirculate different sizes of powdersand/or different types of powders back to a metal powder processingdevice 100.

Referring now back to the front and rear system views of FIGS. 1 and 2,in one embodiment, the powder reclamation system 10 of the presentdisclosure utilizes a carrier gas assembly 28 for generating a pressuredrive system to move the powder 26 from the metal powder processingdevice 100 to the powder reclamation system 10 and throughout the powderreclamation system 10. The carrier gas assembly 28 includes a highpressure carrier gas source 180, and associated pressure drive systemcomponents, that provides and generates the pressure drive system. Inexemplary embodiments, the carrier gas assembly 28 may introduce anargon gas or nitrogen gas pressure drive system throughout the powderreclamation system 10 of the present disclosure.

For the embodiment depicted, the carrier gas assembly 28 is in flowcommunication with the network of passageways 166 for providing thecarrier gas into and through the network of passageways 166. Inparticular, the carrier gas assembly 28 may be configured to replace allgas within the powder reclamation system 10 with the carrier gas. Assuch, the carrier gas assembly 28 may generally include a carrier gassource, a carrier gas pump, one or more carrier gas valves, etc. In sucha manner the carrier gas assembly 28 may provide pressurized carrier gasthrough the network of passageways 166, e.g., to assist with movingpowder through the network of passageways 166.

Referring still to FIGS. 1 and 2, in an exemplary embodiment, a powderreclamation system 10, a powder sieving system assembly 12, and a broadfrequency filter assembly 14 of the present disclosure include a powdermass control assembly 16. The powder mass control assembly 16 isconfigured to determine data indicative of a mass of the powder 26 onthe broad frequency filter 14 and control one or more operations of thepowder sieving system assembly 12 based on the determined dataindicative of the mass of powder 26 on the broad frequency filter 14.

In the embodiment depicted, the powder mass control assembly 16 includesa first load cell 80, a second load cell 82, and a third load cell 84for determining data indicative of a mass of the powder 26 on the broadfrequency filter 14. The first load cell 80 is in communication with theraw reclaimed powder hopper 54 and the first load cell 80 is configuredto measure data indicative of a first mass of powder 26 within the rawreclaimed powder hopper 54.

The second load cell 82 is in communication with the filtered reclaimedpowder hopper 56 and the second load cell 82 is configured to measuredata indicative of a second mass of powder 26 within the filteredreclaimed powder hopper 56.

The third load cell 84 is in communication with the oversized powderhopper 72 and the third load cell 84 is configured to measure dataindicative of a third mass of powder 26 within the oversized powderhopper 72. The first load cell 80, the second load cell 82, and thethird load cell 84 may be mounted at any suitable location to sense dataindicative of a mass of powder within the respective hoppers. Forexample, the first load cell 80, the second load cell 82, and/or thethird load cell 84 may be mounted to the support structure 30 supportingthe respective hopper. Further, the first load cell 80, the second loadcell 82, and the third load cell 84 may be configured as any suitableload cell capable of measuring data indicative of a mass of powderwithin the respective hoppers. Accordingly, it will be appreciated thatthe term “load cell” is meant to generically refer to any sensor capableto measuring data indicative of a mass of powder within a hopper. Forexample, the first load cell 80, the second load cell 82, and/or thethird load cell 84 may include one or more of a strain gauge, apneumatic load cell, a hydraulic load cell, piezoelectric load cell,etc.

The powder mass control assembly 16 is configured to determine dataindicative of the mass of the powder 26 on the broad frequency filter 14using the first load cell 80, the second load cell 82, and the thirdload cell 84.

For example, in at least certain exemplary embodiments the powder masscontrol assembly 16 may first sense data indicative of a mass of powderwithin the raw reclaimed powder hopper 54 prior to providing any rawreclaimed powder to the filter housing 32. The powder mass controlassembly 16 may then provide a desired amount of raw reclaimed powder tothe filter housing 32 and initiate operation of the vibration assembly90. The powder mass control assembly 16 may periodically or continuouslymeasure data indicative of a powder within the filtered reclaimed powderhopper 56 and oversized powder hopper 72 to estimate the amount ofpowder within the filter housing 32 and, e.g., on the first filter 40 ofthe broad frequency filter 14. The powder mass control assembly 16 mayoperate in an open loop control to maintain a desired mass of powder onthe first filter 40 of the broad frequency filter 14.

For example, the powder mass control assembly 16 may control one or moreoperations of the powder sieving system assembly 12 based on thedetermined data indicative of the mass of powder 26 on the broadfrequency filter 14. For example, the powder mass control assembly 16may control a powder flow rate or amount from the raw reclaimed powderhopper 54 to the filter housing 32 based on the determined dataindicative of the mass of powder 26 on the broad frequency filter 14.Additionally, or alternatively, the powder mass control assembly 16 maybe configured to control an intensity, a frequency, or a combinationthereof of the first and second motors 91, 92 of the vibration assembly90 based on the determined data indicative of the mass of powder 26 onthe broad frequency filter 14.

Referring to FIGS. 1 and 2, the powder mass control assembly 16 of thepresent disclosure provides mass control, e.g., load cells 80, 82, 84,above and below the broad frequency filter 14 to ensure for precise massmonitoring and control.

The broad frequency filter 14 of the present disclosure may operate moreefficiently when a certain mass of powder 26 is on the first filter 40of the broad frequency filter 14. Advantageously, the powder masscontrol assembly 16 of the present disclosure controls a mass of thepowder 26 on the broad frequency filter 14 and ensures a desired mass ofthe powder 26 is on the broad frequency filter 14 during operation.Furthermore, the powder mass control assembly 16 controls one or moreoperations of the broad frequency filter 14 based on the determined massof powder 26 on the broad frequency filter 14.

Referring now back to FIGS. 1 and 2, as briefly noted above, in anexemplary embodiment, a powder reclamation system 10 of the presentdisclosure includes a new or virgin powder assembly 20 for introducing anew or virgin powder 130 with a second portion 29 of powder 26, i.e.,filtered reclaimed or recycled powder 29, that is smaller than thepredetermined threshold and passes therethrough the broad frequencyfilter 16. Advantageously, a powder reclamation system 10 of the presentdisclosure including a new or virgin powder assembly 20 provides asystem that is able to introduce and maintain a desired mix of filteredreclaimed powder 29 and virgin powder 130.

In an exemplary embodiment, the new or virgin powder assembly 20includes a virgin powder hopper 132, a powder delivery line 134, and acontroller 136. The virgin powder hopper 132 contains a virgin powder130. The powder delivery line 134 is configured for providing a flow ofpowder to a metal powder processing device 100 (see also, FIG. 12). Thepowder delivery line 134 is in flow communication with the filteredreclaimed powder hopper 56 and the virgin powder hopper 132. In thismanner, the filtered reclaimed powder hopper 56 containing the filteredreclaimed or recycled powder 29 and the virgin powder hopper 132containing the virgin powder 130 are each in flow communication with thepowder delivery line 134 for mixing of the filtered reclaimed powder 29and the virgin powder 130 theretogether. In an exemplary embodiment, thevirgin powder assembly 20 also includes a mixer that is in communicationwith the powder delivery line 134 and that is configured to mix thevirgin powder 130 and the filtered reclaimed powder 29 theretogether.

More particularly, as is depicted in FIG. 1, the powder reclamationsystem 10 further comprises a plurality of valves for regulating a flowof powder to the powder delivery line 134. Specifically, the powderreclamation system 10 includes a filtered powder valve for regulating aflow of filtered powder from the filtered reclaimed powder hopper 56 tothe powder delivery line 134 and a virgin powder valve for regulating aflow of virgin powder from the virgin powder hopper 132 to the powderdelivery line 134. The filtered powder valve and the virgin powder valvemay each be in operable communication with a controller 136 toselectively provide filtered powder and virgin powder to the powderdelivery line 134, and to the metal powder processing device. In oneexemplary embodiment, the controller 136 is operably coupled to apressurized carrier gas source for providing the mixture of the filteredreclaimed powder 29 and the virgin powder 130 through the powderdelivery line 134. The controller 136 is operably coupled to thefiltered powder valve and the virgin powder valve for providing themixture of the filtered reclaimed powder and the virgin powder throughthe powder delivery line 134. For example, the controller 136 isconfigured to sequentially open the filtered powder valve and the virginpowder valve to provide the mixture of the filtered reclaimed powder andthe virgin powder through the powder delivery line 134.

For example, in certain exemplary embodiments, the powder reclamationsystem 10 may be configured to sequentially provide powder 29 from thefiltered reclaimed powder hopper 56 and from the virgin powder hopper132 to ensure the powder provided to the metal powder processing device100 has a desired mixture of filtered reclaimed powder 29 and virginpowder 130.

By way of example only, if ten (10) units of powder are desired to beprovided to the metal powder processing device 100, with an overallcomposition of 6 units of reclaimed filtered powder 29, and 4 units ofvirgin powder 130, the powder reclamation system 10 of the presentdisclosure may sequentially provide powder from the filtered reclaimedpowder hopper 56 and from the virgin powder hopper 132 to provide thedesire amount and composition of powder. For example, the powderreclamation system 10 may sequentially provide two (2) units of powderfrom the filtered reclaimed powder hopper 56 and one (1) unit of powderfrom the virgin powder hopper 132 until a desired amount of powder isprovided to the metal powder processing device 100. With such anexemplary embodiment, the powder reclamation system 10 may go throughmultiple rounds in order to provide the desired amount of powder to themetal powder processing device 100. For example, the powder reclamationsystem 10 may go through at least two rounds, such as at least threerounds, such as up to one hundred rounds.

By providing the powder in multiple rounds of these sequentially oralternating ratios, the powder may have a desired substantiallyhomogenous mixture within the hopper of the metal powder processingdevice 100.

It will be appreciated that although the above-described powderreclamation system 10 is described as being operable with a single metalpowder processing device, in other embodiments, the powder reclamationsystem 10 of the present disclosure may additionally or alternatively beoperable with a plurality of metal powder processing devices. Forexample, referring now to FIG. 19, in an exemplary embodiment, a powderreclamation system 10 of the present disclosure includes a multiplemetal powder processing device attachment assembly 22 for allowing thepowder reclamation system 10 to connect to and recover powder from aplurality of metal powder processing devices.

A powder reclamation system 10 of the present disclosure may be operablewith a plurality of metal powder processing devices in a variety ofdifferent configurations, such as in series, in parallel, or in otherhybrid configurations. For example, in one exemplary embodiment, apowder reclamation system 10 can be directly connected to a plurality ofmetal powder processing devices as shown in FIG. 19. In other exemplaryembodiments, a powder reclamation system 10 can be directly connected toa first metal powder processing device and indirectly connected to asecond metal powder processing device which is directly connected to thefirst metal powder processing device. In other words, a powderreclamation system 10 can be connected to a first metal powderprocessing device which is connected to a second metal powder processingdevice in a series configuration.

In an exemplary embodiment, the multiple metal powder processing deviceattachment assembly 22 includes a multi-source input attachment system140 having a first connection portion 142 for connecting the powderreclamation system 10 to a first metal powder processing device 100 anda second connection portion 144 for connecting the powder reclamationsystem 10 to a second metal powder processing device 102. Although FIG.19 illustrates the powder reclamation system 10 connected with a firstand second metal powder processing device 100, 102, it is contemplatedthat the multiple metal powder processing device attachment assembly 22of the present disclosure can be used to connect any number of metalpowder processing devices to a powder reclamation system 10 of thepresent disclosure.

In an exemplary embodiment, a powder reclamation system 10 of thepresent disclosure includes a first reclamation passageway 50 and asecond reclamation passageway 150. For example, referring to FIG. 19,the first reclamation passageway 50 is in communication with the rawreclaimed powder hopper 54 and a first metal powder processing device100 via the first connection portion 142 of the multi-source inputattachment system 140. The first reclamation passageway 50 is configuredto recover a first unused portion of a first powder from the first metalpowder processing device 100 to the raw reclaimed powder hopper 54.

Referring to FIG. 19, the second reclamation passageway 150 is incommunication with the raw reclaimed powder hopper 54 and a second metalpowder processing device 102 via the second connection portion 144 ofthe multi-source input attachment system 140. The second reclamationpassageway 150 is configured to recover a second unused portion of asecond powder from the second metal powder processing device 102 to theraw reclaimed powder hopper 54. In this manner, both of the first unusedportion of a first powder from the first metal powder processing device100 and the second unused portion of a second powder from the secondmetal powder processing device 102 reach the raw reclaimed powder hopper54. Next, the first powder and the second powder go through a filteringprocess with the broad frequency filter 14 as described herein. Thebroad frequency filter 14 is configured to restrict a first portion ofthe first and second powders larger than a predetermined threshold fromreaching the outlet 36 of the filter housing 32 and to allow a secondportion of the first and second powders smaller than the predeterminedthreshold to pass through the first filter 40, the second filter 42, andthe outlet 36 of the filter housing 32. Next, the second portion of thefirst and second powders is received within the filtered reclaimedpowder hopper 56 in communication with the outlet 36 of the filterhousing 32.

It is also contemplated that the broad frequency filter 14 may include aseparator that is configured to separate a first portion of the firstand second powders from a second portion of the first and secondpowders. For example, the broad frequency filter 14 including aseparator, in addition to being able to filter by powder sizes, may alsobe able to separate based on different types of powders, to removeclumps, and/or other separation criteria.

In an exemplary embodiment, a powder reclamation system 10 of thepresent disclosure includes a first recirculation passageway 52 and asecond recirculation passageway 152. For example, referring to FIG. 19,the first recirculation passageway 52 is in communication with thefiltered reclaimed powder hopper 56 and the first metal powderprocessing device 100. The first recirculation passageway 52 isconfigured to recirculate a first part of the second portion of thefirst and second powders back to the first metal powder processingdevice 100.

Referring to FIG. 19, the second recirculation passageway 152 is incommunication with the filtered reclaimed powder hopper 56 and thesecond metal powder processing device 102. The second recirculationpassageway 152 is configured to recirculate a second part of the secondportion of the first and second powders back to the second metal powderprocessing device 102.

Furthermore, in an exemplary embodiment, the multiple metal powderprocessing device attachment assembly 22 includes a controller 154 thatis in communication with a portion of the powder reclamation system 10and/or the metal powder processing devices. For example, in oneembodiment, the controller 154 is in communication with the rawreclaimed powder hopper 54 and/or the metal powder processing devices.The controller 154 is operable to control an amount of the first unusedportion of the first powder that is recovered from the first metalpowder processing device 100 to the raw reclaimed powder hopper 54 andcontrol an amount of the second unused portion of the second powder thatis recovered from the second metal powder processing device 102 to theraw reclaimed powder hopper 54.

In an exemplary embodiment, the multiple metal powder processing deviceattachment assembly 22 also includes a second controller 156 that is incommunication with a portion of the powder reclamation system 10 and/orthe metal powder processing devices. For example, in one embodiment, thesecond controller 156 is in communication with the virgin powder hopper132 and/or the metal powder processing devices. The second controller156 is operable to selectively dose the second portion of the first andsecond powders with the virgin powder 130 at a location upstream of thefirst and second metal powder processing devices 100, 102.

More particularly, as is depicted in FIG. 19, the powder reclamationsystem 10 including a multiple metal powder processing device attachmentassembly 22 further includes a plurality of valves for regulating a flowof powder from the metal powder processing devices and back to the metalpowder processing devices. Specifically, the powder reclamation system10 includes a reclamation valve for regulating a flow of a recoveredfirst powder from the first metal powder processing device 100 to theraw reclaimed powder hopper 54 via the first reclamation passageway 50and regulating a flow of a recovered second powder from the second metalpowder processing device 102 to the raw reclaimed powder hopper 54. Thesystem 10 also includes a recirculation valve for regulating a flow of arecirculated first part of the second portion of the first and secondpowders back to the first metal powder processing device 100 via thefirst recirculation passageway 52 and regulating a flow of arecirculated second part of the second portion of the first and secondpowders back to the second metal powder processing device 102 via thesecond recirculation passageway 152. The reclamation valve and therecirculation valve may each be in operable communication with acontroller 154, 156 to selectively recover powder from the metal powderprocessing devices 100, 102 and to selectively recirculate powder backto the metal powder processing devices 100, 102. In one exemplaryembodiment, the controllers 154, 156 are operably coupled to apressurized carrier gas source for recovering powder from the metalpowder processing devices 100, 102 and for recirculating powder back tothe metal powder processing devices 100, 102.

Furthermore, the controllers 154, 156 of the multiple metal powderprocessing device attachment assembly 22 can provide different pressuresof a carrier gas flow through the respective passageways, e.g., thefirst reclamation passageway 50, the second reclamation passageway 150,the first recirculation passageway 52, and the second recirculationpassageway 152, coupling the powder reclamation system 10 to respectivemetal powder processing devices 100, 102.

The controllers 154, 156 of the multiple metal powder processing deviceattachment assembly 22 can also reclaim powder simultaneously frommultiple metal powder processing devices, or sequentially. Additionally,the controllers 154, 156 of the multiple metal powder processing deviceattachment assembly 22 can also recirculate or provide powdersimultaneously to multiple metal powder processing devices, orsequentially.

In an exemplary embodiment of the present disclosure, the passageways ofrespective portions of the multiple metal powder processing deviceattachment assembly 22 of a powder reclamation system 10 may includedifferent configurations, sizes, and dimensions. For example, the firstreclamation passageway 50 defines a first cross-sectional area and thesecond reclamation passageway 150 defines a second cross-sectional area.In one embodiment, the first cross-sectional area of the firstreclamation passageway 50 is different than the second cross-sectionalarea of the second reclamation passageway 150. In some embodiments, thefirst cross-sectional area of the first reclamation passageway 50 may bethe same as the second cross-sectional area of the second reclamationpassageway 150. Furthermore, the first reclamation passageway 50 definesa first length and the second reclamation passageway 150 defines asecond length. In one embodiment, the second length of the secondreclamation passageway 150 is greater than the first length of the firstreclamation passageway 50, and the first cross-sectional area is lessthan the second cross-sectional area. Thus, in some embodiments, thesizes, lengths, and dimensions of the first reclamation passageway 50and the second reclamation passageway 150 are different.

Furthermore, as noted above, the powder reclamation system 10 may beutilized to reclaim, filter, and distribute reactive metal powders toone or more metal powder processing devices. As such, it may bebeneficial to include features to ensure an internal environment of thepowder reclamation system 10 is sufficiently devoid of oxygen to preventan undesirable reaction between the powder and oxygen.

Specifically, referring still to FIGS. 1 and 2, in an exemplaryembodiment, a powder reclamation system 10 of the present disclosureincludes an oxygen sensing assembly 24 of the present disclosure thatmonitors an amount of oxygen within the powder reclamation system 10 ofthe present disclosure. The oxygen sensing assembly 24 of the presentdisclosure includes a sensor for monitoring the amount of oxygen withinthe powder reclamation system 10 and the oxygen sensing assembly 24 isconfigured to initiate a corrective action in response to receiving dataindicative of the amount of oxygen within the powder reclamation system10 exceeding a predetermined threshold.

In an exemplary embodiment, the oxygen sensing assembly 24 of thepresent disclosure includes a sensor assembly 24 that is incommunication with a portion of the powder reclamation system 10 and thepowder sieving system 12. The sensor assembly 24 is configured tomonitor an amount of oxygen within a network of passageways 166 of thepowder reclamation system 10. For example, in one exemplary embodiment,the network of passageways 166 include the reclamation passageways 50,150, the recirculation passageways 52, 152, the raw reclaimed powderhopper 54, the filtered reclaimed powder hopper 56, the oversized powderhopper 72, the virgin powder hopper 132, the multi-source inputattachment system 140, and/or other connecting passageways throughoutthe powder reclamation system 10.

As described above, in one embodiment, the powder reclamation system 10of the present disclosure utilizes a carrier gas assembly 28 forgenerating a pressure drive system to move a powder 26 from a metalpowder processing device 100 to the powder reclamation system 10 andthroughout the powder reclamation system 10. In exemplary embodiments,the carrier gas assembly 28 may introduce an argon gas or nitrogen gaspressure drive system throughout the powder reclamation system 10 of thepresent disclosure.

In this manner, the carrier gas assembly 28 provides a pressure drivesystem for moving a powder 26 through the network of passageways 166 ofthe powder reclamation system 10 that is configured to recover a powder26 from a machine 100, to move a powder 26 to the filter housing 32 forfiltering, and to recirculate a portion of the powder 26 that passesthrough the filter housing 32 back to the machine 100.

In one exemplary embodiment, the sensor assembly 24 includes a firstsensor 162 and a second sensor 164. The first sensor 162 is incommunication with a portion of the powder sieving system 12. Forexample, referring to FIGS. 1 and 13, the first sensor 162 is incommunication with a portion of the broad frequency filter 14, e.g., thefilter housing 32. The first sensor 162 is configured to monitor anamount of oxygen within the network of passageways 166.

The second sensor is in communication with a second portion of thepowder sieving system 12. For example, referring to FIG. 1, the secondsensor 164 is in communication with a portion of the raw reclaimedpowder hopper 54. The second sensor 164 is spaced apart from the firstsensor 162; and the second sensor 164 is configured to monitor theamount of oxygen within the network of passageways 166.

In one embodiment, the first sensor 162 and the second sensor 164 areoptical sensors. More specifically, referring now to FIG. 3, providing aclose-up, view of the first sensor 162, the first sensor generally sendslasers to detect an oxygen level throughout a powder reclamation system10 of the present disclosure. In this manner, the sensors 162, 164 donot heat up air which may be dangerous because of the powder 26 therein.

As described above, a powder 26 that is recovered, filtered, andrecirculated by a powder reclamation system 10 of the present disclosuremay be reactive with oxygen. Advantageously, the oxygen sensing assembly24 of the present disclosure monitors an amount of oxygen within thepowder reclamation system 10 of the present disclosure to prevent apowder 26 from reacting with oxygen. Additionally, by having opticalsensors, the sensors 162, 164 send lasers to detect an oxygen levelthroughout a powder reclamation system 10 of the present disclosure. Inthis manner, the sensors 162, 164 do not heat up air which is dangerousbecause of the powder 26 therein.

As noted, the powder reclamation system may be configured to initiate acorrective action in response to receiving data indicative of an oxygencontent being above a predetermined oxygen threshold.

In an exemplary embodiment, the oxygen sensing assembly 24 includes acontroller 174 that is operably coupled to the sensor assembly 24, e.g.,the first sensor 162, for receiving data indicative of the amount ofoxygen within the network of passageways 166 from the first sensor 162.The controller 174 of the oxygen sensing assembly 24 is configured toinitiate a corrective action in response to receiving data indicative ofthe amount of oxygen within the network of passageways 166 being above apredetermined oxygen threshold. In one exemplary embodiment, thepredetermined oxygen threshold is a 4% oxygen content within the networkof passageways 166 of the powder reclamation system 10. In anotherexemplary embodiment, the predetermined oxygen threshold is a 1% oxygencontent within the network of passageways 166 of the powder reclamationsystem 10.

In one embodiment, the controller 174 of the oxygen sensing assembly 24initiates a corrective action by shutting down a powder flow within thenetwork of passageways 166. Furthermore, the controller 174 of theoxygen sensing assembly 24 initiates a corrective action by providingadditional carrier gas to the network of passageways 166.

In some exemplary embodiments, the first sensor 162, the second sensor164, and the controller 174 of the oxygen sensing assembly 24 areconfigured to shut down a powder flow throughout the powder reclamationsystem 10 if the amount of oxygen detected within the network ofpassageways 166 exceeds 4 percent. In another embodiment, the firstsensor 162, the second sensor 164, and the controller 174 of the oxygensensing assembly 24 are configured to shut down a powder flow throughoutthe powder reclamation system 10 if the amount of oxygen detected withinthe network of passageways 166 exceeds 1 percent.

In exemplary embodiments, the sensor assembly 24 may include additionalsensors. For example, referring to FIG. 1, the sensor assembly 24 mayinclude a third sensor 168, a fourth sensor 170, and a fifth sensor 172.For example, referring to FIG. 1, the first sensor 162 is incommunication with a first portion of the powder sieving system 12 andthe second sensor 164 is in communication with a second portion of theof the powder sieving system 12, e.g., raw reclaimed powder hopper 54.In this manner, the second sensor 164 is spaced apart from the firstsensor 162. Furthermore, in one exemplary embodiment, the third sensor168 is in communication with a portion of the filtered reclaimed powderhopper 56. The third sensor 168 is also configured to monitor the amountof oxygen within the network of passageways 166. The fourth sensor 170is in communication with a portion downstream of the virgin powderhopper 132. The fourth sensor 170 is also configured to monitor theamount of oxygen within the network of passageways 166. The fifth sensor172 is in communication with a portion of the oversized powder hopper72. The fifth sensor 172 is also configured to monitor the amount ofoxygen within the network of passageways 166.

It will be appreciated that in other exemplary embodiments of thepresent disclosure, the above-described powder reclamation system mayhave any other suitable configurations. For example, in other exemplaryembodiments, a powder reclamation system of the present disclosure maybe compatible with other filter assemblies. For example, although afilter assembly of the present disclosure is described as a broadfrequency filter, it is contemplated that other filters and filterassemblies may be utilized with the system of the present disclosure.

Moreover, it will be appreciated that in certain exemplary embodiments,the sieving system assembly described herein may not be incorporatedinto a powder reclamation system, and instead may be a stand-alonesieving system utilized in, e.g., powder manufacturing to obtain desiredpowder size distributions.

For example, referring now to FIGS. 14 and 15, a perspective view andstraight-on view of a sieving system assembly 212 in accordance with thepresent disclosure is provided. The exemplary sieving system assembly212 depicted in FIGS. 14 and 15 may be configured in substantially thesame manner as the exemplary sieving system assembly 12 described aboveas being incorporated into a powder reclamation system 10. For example,the exemplary sieving system assembly 212 depicted includes a raw powderhopper 254 (which in the embodiments of the powder reclamation system 10is a raw reclaimed powder hopper 54); a filter housing 232 moveablerelative to a support structure 230 by a vibration assembly 290; afiltered powder hopper 256 (which in the embodiments of the powderreclamation system 10 is a filtered reclaimed powder hopper 56); anoversized powder hopper 272; a powder isolation assembly 218 connectingthe raw powder hopper 254 to the filter housing 232, the filter housing232 to the filtered powder hopper 256, and the filter housing 232 to theoversized powder hopper 272; and a mechanical isolation assembly 257(having one or more dampers or springs 258 mechanically isolating thefilter housing 232 relative to the support structure 230 duringoperation of the vibration assembly 290). Further, although notdepicted, the sieving system assembly 212 may further include a powdermass control system, an oxygen sensing system, etc., such as the systems14, 16, 20, 24 described in detail above.

It will be appreciated, however, that for the exemplary sieving systemassembly 212 depicted, the sieving system 212 is configured to separatethe raw powder into multiple powder distribution sizes. In particular,the exemplary sieving system assembly 212 includes a fine filteredpowder hopper 292 for powder below a lower threshold; a middle filteredpowder hopper 294 for powder within a size distribution range greaterthan the lower threshold; and a course filtered powder hopper 296 forpowder larger than the size distribution range greater than the lowerthreshold. It is also contemplated that other configurations ofseparating raw powder into multiple powder distribution sizes includingany number of different sized filtered hoppers may be included with asieving system 212 of the present disclosure.

Specifically, referring now also to FIG. 16, providing a close-up,cross-sectional view of a portion of the filter housing 232 of a sievingsystem assembly 212, the filter housing 232 includes a first broadfrequency filter assembly 274 including a first filter 240 and secondfilter 242 and a second broad frequency filter assembly 276 alsoincluding a first filter 277 and a second filter 278. The first broadfrequency filter assembly 274 is spaced apart from the second broadfrequency filter assembly 276 and allows a sieving system assembly 212of the present disclosure to provide multiple stages of filtering. Forexample, the first set of filters 274 define a first pore size and thesecond set of filters 276 define a second pore size. In one embodiment,the second pore size is greater than the first pore size.

In an exemplary embodiment, the outlet 236 of the filter housing 232 isa first outlet 236 and the filter housing 232 further defines a secondoutlet 238 and a third outlet 239. As described above, the broadfrequency filter 214 includes a first set of filters, e.g., a firstbroad frequency filter assembly 274, and a second set of filters, e.g.,a second broad frequency filter assembly 276. The first outlet 236 ispositioned downstream of the first and second sets of filters 274, 276,the second outlet 238 is positioned upstream of the first set of filters276 and downstream of the second set of filters 274, and the thirdoutlet 239 is positioned upstream of the first and second sets offilters 274, 276. FIG. 17 shows the second outlet 238 that is locatedbetween the first set of filters 274 and the second sets of filters 276.

Referring now to FIG. 20, a method 500 of reclaiming powder inaccordance with an exemplary aspect of the present disclosure isdepicted. The exemplary method 500 may be utilized to operate one ormore of the exemplary powder reclamation systems and/or sieving systemsdescribed above with reference to FIGS. 1 through 19.

For the exemplary aspect of FIG. 20, the method 500 generally includesat (502) recovering an unused portion of a powder from a metal powderprocessing device.

The method 500 further includes at (504) providing the unused portion ofthe powder to a broad frequency filter as described in detail above withreference to one or more of the exemplary powder reclamation systemsand/or sieving systems described above with reference to FIGS. 1 through19.

For the exemplary aspect depicted, the method 500 further includes at(506) separating a first portion of the powder larger than apredetermined threshold from a second portion of the powder smaller thanthe predetermined threshold using the broad frequency filter. For theexemplary aspect depicted, separating the first portion of the powderlarger than the predetermined threshold from the second portion of thepowder smaller than the predetermined threshold using the broadfrequency filter includes at (508) moving the filter housing relative tothe support structure and simultaneously moving the second filterrelative to the first filter within the filter housing to restrict thefirst portion of the powder larger than the predetermined threshold fromreaching the outlet of the filter housing and to allow the secondportion of the powder smaller than the predetermined threshold to passthrough the first filter, the second filter, and the outlet of thefilter housing.

The method 500 further includes at (510) recirculating the secondportion of the powder back to the metal powder processing device.

Referring now to FIG. 21, a method 600 of reclaiming powder inaccordance with another exemplary aspect of the present disclosure isdepicted. The exemplary method 600 may be utilized to operate one ormore of the exemplary powder reclamation systems and/or sieving systemsdescribed above with reference to FIGS. 1 through 19.

For the exemplary aspect of FIG. 21, the method 600 generally includesat (602) recovering an unused portion of a powder from a metal powderprocessing device.

The method 600 further includes at (604) providing the unused portion ofthe powder to a broad frequency filter as described in detail above withreference to one or more of the exemplary powder reclamation systemsand/or sieving systems described above with reference to FIGS. 1 through19.

For the exemplary aspect depicted, the method 600 further includes at(606) controlling a mass of the powder on the broad frequency filter. Ina first exemplary aspect depicted, controlling the mass of the powder onthe broad frequency filter includes at (608) determining a first mass ofpowder at a location upstream of the broad frequency filter anddetermining a second mass of powder at a location downstream of thebroad frequency filter.

Referring now to FIG. 22, a method 700 of reclaiming powder inaccordance with an exemplary aspect of the present disclosure isdepicted. The exemplary method 700 may be utilized to operate one ormore of the exemplary powder reclamation systems and/or sieving systemsdescribed above with reference to FIGS. 1 through 19.

For the exemplary aspect of FIG. 22, the method 700 generally includesat (702) recovering an unused portion of a powder from a metal powderprocessing device.

The method 700 further includes at (704) separating a first portion ofthe recovered unused powder larger than a predetermined threshold from asecond portion of the recovered unused powder smaller than thepredetermined threshold using a filter, the second portion of therecovered unused powder being a filtered reclaimed powder after passingthrough the filter.

The method 700 further includes at (706) selectively providing a portionof the filtered reclaimed powder and a virgin powder to a powderrecirculation passageway.

The method 700 further includes at (708) providing a mixture of thefiltered reclaimed powder and the virgin powder through the powderrecirculation passageway and to the metal powder processing device.

Referring now to FIG. 23, a method 800 of reclaiming powder inaccordance with an exemplary aspect of the present disclosure isdepicted. The exemplary method 800 may be utilized to operate one ormore of the exemplary powder reclamation systems and/or sieving systemsdescribed above with reference to FIGS. 1 through 19.

For the exemplary aspect of FIG. 23, the method 800 generally includesat (802) recovering a first unused portion of a first powder from afirst metal powder processing device. The method 800 further includes at(804) recovering a second unused portion of a second powder from asecond metal powder processing device.

The method 800 includes at (806) providing the first unused portion ofthe first powder and the second unused portion of the second powder to ahousing of a powder reclamation system comprising a separator asdescribed in detail above with reference to one or more of the exemplarypowder reclamation systems and/or sieving systems described above withreference to FIGS. 1 through 19.

For the exemplary aspect depicted, the method 800 further includes at(808) separating a first portion of the first and second powders from asecond portion of the first and second powders using the separator.

The method 800 includes at (810) recirculating a first part of thesecond portion of the first and second powders back to the first metalpowder processing device. The method 800 further includes at (812)recirculating a second part of the second portion of the first andsecond powders back to the second metal powder processing device.

Referring now to FIG. 24, a method 900 of operating a sieving system inaccordance with an exemplary aspect of the present disclosure isdepicted. The exemplary method 900 may be utilized to operate one ormore of the exemplary sieving systems described above with reference toFIGS. 1 through 19.

For the exemplary aspect of FIG. 24, the method 900 generally includesat (902) providing a carrier gas flow and a mixture flow through anetwork of passageways of the sieving system, the mixture flowcomprising a carrier gas and a reactive metal powder.

In an exemplary embodiment, a system of the present disclosure providesa carrier gas flow and a mixture flow through a network of passagewaysof the system that has a ratio of gas (e.g., in kg) to powder (e.g., inkg) below approximately 1:6.

In other exemplary embodiments, a system of the present disclosureprovides a carrier gas flow and a mixture flow through a network ofpassageways of the system that has a ratio of gas (e.g., in kg) topowder (e.g., in kg) below approximately 1:10.

In other exemplary embodiments, a system of the present disclosureprovides a carrier gas flow and a mixture flow through a network ofpassageways of the system that has a ratio of gas (e.g., in kg) topowder (e.g., in kg) below approximately 1:5.

In other exemplary embodiments, a system of the present disclosureprovides a carrier gas flow and a mixture flow through a network ofpassageways of the system that has other ratios of gas (e.g., in kg) topowder (e.g., in kg).

In some exemplary embodiments, a system of the present disclosureincludes a first region that provides a carrier gas flow and a mixtureflow through a network of passageways of the system that has a firstratio of gas (e.g., in kg) to powder (e.g., in kg) and includes a secondregion that provides a carrier gas flow and a mixture flow through anetwork of passageways of the system that has a second ratio of gas(e.g., in kg) to powder (e.g., in kg) that is different than the firstratio.

The method 900 further includes at (904) separating a first portion ofthe reactive metal powder larger than a predetermined threshold from asecond portion of the reactive metal powder smaller than thepredetermined threshold within a filter housing of the sieving systemusing a filter.

The method 900 further includes at (906) determining an amount of oxygenwithin the powder reclamation system is above a predetermined threshold.

The method 900 further includes at (908) initiating a corrective actionin response to determining the amount of oxygen within the powderreclamation system is above the predetermined threshold.

Further aspects of the invention are provided by the subject matter ofthe following clauses:

1. A powder reclamation system, comprising: a support structure; afilter housing movable relative to the support structure, the filterhousing defining an inlet and an outlet; a raw reclaimed powder hopperin communication with the inlet of the filter housing; a firstreclamation passageway in communication with the raw reclaimed powderhopper and configured to be in communication with a first metal powderprocessing device to recover a first unused portion of a first powderfrom the first metal powder processing device to the raw reclaimedpowder hopper; and a second reclamation passageway in communication withthe raw reclaimed powder hopper and configured to be in communicationwith a second metal powder processing device to recover a second unusedportion of a second powder from the second metal powder processingdevice to the raw reclaimed powder hopper.

2. The powder reclamation system of any preceding clause, furthercomprising: a broad frequency filter disposed between the inlet and theoutlet of the filter housing, the broad frequency filter configured torestrict a first portion of the first and second powders larger than apredetermined threshold from reaching the outlet and to allow a secondportion of the first and second powders smaller than the predeterminedthreshold to pass therethrough.

3. The powder reclamation system of any preceding clause, furthercomprising: a filtered reclaimed powder hopper in communication with theoutlet of the filter housing, wherein the filtered reclaimed powderhopper receives the second portion of the first and second powders thatpasses through the broad frequency filter.

4. The powder reclamation system of any preceding clause, furthercomprising: a first recirculation passageway in communication with thefiltered reclaimed powder hopper and configured to be in communicationwith the first metal powder processing device to recirculate a firstpart of the second portion of the first and second powders back to thefirst metal powder processing device.

5. The powder reclamation system of any preceding clause, furthercomprising: a second recirculation passageway in communication with thefiltered reclaimed powder hopper and configured to be in communicationwith the second metal powder processing device to recirculate a secondpart of the second portion of the first and second powders back to thesecond metal powder processing device.

6. The powder reclamation system of any preceding clause, furthercomprising: a virgin powder hopper comprising a virgin powder; and acontroller operable to selectively dose the second portion of the firstand second powders with the virgin powder at a location upstream of thefirst and second metal powder processing devices.

7. The powder reclamation system of any preceding clause, wherein thebroad frequency filter comprises: a first filter fixed relative to thefilter housing, the first filter being substantially rigid; and a secondfilter coupled within the filter housing adjacent to the first filter,the second filter being substantially flexible such that the secondfilter is movable relative to the first filter within the filter housingwhen the filter housing moves relative to the support structure.

8. The powder reclamation system of any preceding clause, furthercomprising: a controller operable to control an amount of the firstunused portion of the first powder that is recovered from the firstmetal powder processing device to the raw reclaimed powder hopper andcontrol an amount of the second unused portion of the second powder thatis recovered from the second metal powder processing device to the rawreclaimed powder hopper.

9. The powder reclamation system of any preceding clause, wherein thefirst reclamation passageway defines a first cross-sectional area,wherein the second reclamation passageway defines a secondcross-sectional area, and wherein the first cross-sectional area isdifferent than the second cross-sectional area.

10. The powder reclamation system of any preceding clause, wherein thefirst reclamation passageway defines a first length, wherein the secondreclamation passageway defines a second length greater than the firstlength, and wherein the first cross-sectional area is less than thesecond cross-sectional area.

11. A method of reclaiming powder using a powder reclamation system, themethod comprising: recovering a first unused portion of a first powderfrom a first metal powder processing device; recovering a second unusedportion of a second powder from a second metal powder processing device;providing the first unused portion of the first powder and the secondunused portion of the second powder to a housing of a powder reclamationsystem comprising a separator; separating a first portion of the firstand second powders from a second portion of the first and second powdersusing the separator; recirculating a first part of the second portion ofthe first and second powders back to the first metal powder processingdevice; and recirculating a second part of the second portion of thefirst and second powders back to the second metal powder processingdevice.

12. The method of any preceding clause, wherein recovering the firstunused portion of the first powder from the first metal powderprocessing device comprises controlling an amount of the first unusedportion of the first powder that is recovered from the first metalpowder processing device.

13. The method of any preceding clause, wherein recovering the secondunused portion of the second powder from the second metal powderprocessing device comprises controlling an amount of the second unusedportion of the second powder that is recovered from the second metalpowder processing device.

14. The method of any preceding clause, wherein controlling the amountof the first unused portion of the first powder that is recovered fromthe first metal powder processing device comprises controlling aparameter of a carrier gas flow through a first reclamation passageway.

15. The method of any preceding clause, wherein recirculating the firstpart of the second portion of the first and second powders back to thefirst metal powder processing device comprises controlling an amount ofthe first part of the second portion of the first and second powdersthat is recirculated back to the first metal powder processing device.

16. The method of any preceding clause, wherein recirculating the secondpart of the second portion of the first and second powders back to thesecond metal powder processing device comprises controlling an amount ofthe second part of the second portion of the first and second powdersthat is recirculated back to the second metal powder processing device.

17. The method of any preceding clause, wherein controlling the amountof the first part of the second portion of the first and second powdersthat is recirculated back to the first metal powder processing devicecomprises controlling a parameter of a carrier gas flow through a firstrecirculation passageway.

18. The method of any preceding clause, further comprising: determiningan operating parameter of the powder reclamation system; and controllingthe recovering the first and second unused portions of the first andsecond powders in response to the operating parameter of the powderreclamation system.

19. The method of any preceding clause, further comprising: determiningan operating parameter of the powder reclamation system; and controllingthe recirculating the first and second parts of the second portion ofthe first and second powders in response to the operating parameter ofthe powder reclamation system.

20. The method of any preceding clause, further comprising: determiningan operating parameter of the first metal powder processing device, ofthe second metal powder processing device, or both; and controlling therecirculating the first and second parts of the second portion of thefirst and second powders in response to the determined operatingparameter.

21. The method of any preceding clause, further comprising: determininga need for additional powder for the first metal powder processingdevice, for the second metal powder processing device, or both; andcontrolling the recirculating the first and second parts of the secondportion of the first and second powders in response to the determinedneed for additional powder.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they include structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

While this disclosure has been described as having exemplary designs,the present disclosure can be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the disclosure using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this disclosure pertains and which fallwithin the limits of the appended claims.

What is claimed is:
 1. A powder reclamation system, comprising: asupport structure; a filter housing movable relative to the supportstructure, the filter housing defining an inlet and an outlet; a rawreclaimed powder hopper in communication with the inlet of the filterhousing; a first reclamation passageway in communication with the rawreclaimed powder hopper and configured to be in communication with afirst metal powder processing device to recover a first unused portionof a first powder from the first metal powder processing device to theraw reclaimed powder hopper; and a second reclamation passageway incommunication with the raw reclaimed powder hopper and configured to bein communication with a second metal powder processing device to recovera second unused portion of a second powder from the second metal powderprocessing device to the raw reclaimed powder hopper.
 2. The powderreclamation system of claim 1, further comprising: a broad frequencyfilter disposed between the inlet and the outlet of the filter housing,the broad frequency filter configured to restrict a first portion of thefirst and second powders larger than a predetermined threshold fromreaching the outlet and to allow a second portion of the first andsecond powders smaller than the predetermined threshold to passtherethrough.
 3. The powder reclamation system of claim 2, furthercomprising: a filtered reclaimed powder hopper in communication with theoutlet of the filter housing, wherein the filtered reclaimed powderhopper receives the second portion of the first and second powders thatpasses through the broad frequency filter.
 4. The powder reclamationsystem of claim 3, further comprising: a first recirculation passagewayin communication with the filtered reclaimed powder hopper andconfigured to be in communication with the first metal powder processingdevice to recirculate a first part of the second portion of the firstand second powders back to the first metal powder processing device. 5.The powder reclamation system of claim 4, further comprising: a secondrecirculation passageway in communication with the filtered reclaimedpowder hopper and configured to be in communication with the secondmetal powder processing device to recirculate a second part of thesecond portion of the first and second powders back to the second metalpowder processing device.
 6. The powder reclamation system of claim 5,further comprising: a virgin powder hopper comprising a virgin powder;and a controller operable to selectively dose the second portion of thefirst and second powders with the virgin powder at a location upstreamof the first and second metal powder processing devices.
 7. The powderreclamation system of claim 2, wherein the broad frequency filtercomprises: a first filter fixed relative to the filter housing, thefirst filter being substantially rigid; and a second filter coupledwithin the filter housing adjacent to the first filter, the secondfilter being substantially flexible such that the second filter ismovable relative to the first filter within the filter housing when thefilter housing moves relative to the support structure.
 8. The powderreclamation system of claim 1, further comprising: a controller operableto control an amount of the first unused portion of the first powderthat is recovered from the first metal powder processing device to theraw reclaimed powder hopper and control an amount of the second unusedportion of the second powder that is recovered from the second metalpowder processing device to the raw reclaimed powder hopper.
 9. Thepowder reclamation system of claim 1, wherein the first reclamationpassageway defines a first cross-sectional area, wherein the secondreclamation passageway defines a second cross-sectional area, andwherein the first cross-sectional area is different than the secondcross-sectional area.
 10. The powder reclamation system of claim 9,wherein the first reclamation passageway defines a first length, whereinthe second reclamation passageway defines a second length greater thanthe first length, and wherein the first cross-sectional area is lessthan the second cross-sectional area.
 11. A method of reclaiming powderusing a powder reclamation system, the method comprising: recovering afirst unused portion of a first powder from a first metal powderprocessing device; recovering a second unused portion of a second powderfrom a second metal powder processing device; providing the first unusedportion of the first powder and the second unused portion of the secondpowder to a housing of a powder reclamation system comprising aseparator; separating a first portion of the first and second powdersfrom a second portion of the first and second powders using theseparator; recirculating a first part of the second portion of the firstand second powders back to the first metal powder processing device; andrecirculating a second part of the second portion of the first andsecond powders back to the second metal powder processing device. 12.The method of claim 11, wherein recovering the first unused portion ofthe first powder from the first metal powder processing device comprisescontrolling an amount of the first unused portion of the first powderthat is recovered from the first metal powder processing device.
 13. Themethod of claim 12, wherein recovering the second unused portion of thesecond powder from the second metal powder processing device comprisescontrolling an amount of the second unused portion of the second powderthat is recovered from the second metal powder processing device. 14.The method of claim 12, wherein controlling the amount of the firstunused portion of the first powder that is recovered from the firstmetal powder processing device comprises controlling a parameter of acarrier gas flow through a first reclamation passageway.
 15. The methodof claim 11, wherein recirculating the first part of the second portionof the first and second powders back to the first metal powderprocessing device comprises controlling an amount of the first part ofthe second portion of the first and second powders that is recirculatedback to the first metal powder processing device.
 16. The method ofclaim 11, wherein recirculating the second part of the second portion ofthe first and second powders back to the second metal powder processingdevice comprises controlling an amount of the second part of the secondportion of the first and second powders that is recirculated back to thesecond metal powder processing device.
 17. The method of claim 15,wherein controlling the amount of the first part of the second portionof the first and second powders that is recirculated back to the firstmetal powder processing device comprises controlling a parameter of acarrier gas flow through a first recirculation passageway.
 18. Themethod of claim 11, further comprising: determining an operatingparameter of the powder reclamation system; and controlling therecovering the first and second unused portions of the first and secondpowders in response to the operating parameter of the powder reclamationsystem.
 19. The method of claim 11, further comprising: determining anoperating parameter of the powder reclamation system; and controllingthe recirculating the first and second parts of the second portion ofthe first and second powders in response to the operating parameter ofthe powder reclamation system.
 20. The method of claim 11, furthercomprising: determining an operating parameter of the first metal powderprocessing device, of the second metal powder processing device, orboth; and controlling the recirculating the first and second parts ofthe second portion of the first and second powders in response to thedetermined operating parameter.
 21. The method of claim 11, furthercomprising: determining a need for additional powder for the first metalpowder processing device, for the second metal powder processing device,or both; and controlling the recirculating the first and second parts ofthe second portion of the first and second powders in response to thedetermined need for additional powder.